BW 2 24 04 / 1 Content 1. Scope of delivery 2. Device description 3. Installation 4. Operation 5. Shutdown 6. Maintenance 7. Troubleshooting 1 Scope of delivery The chlorine gas changeover unit C 7520 is delivered either as a ready-to-connect unit with a mounting plate or an assembly kit for integration in the pipe line. When unpacking, please ensure that the installation material (included in the scope of delivery) for wall fixing is not lost. 2 Device description 2.1 Technical data Description Throughput Chlorine gas up to 200 kg/h Connections depending on the device version Voltage supply Fluid chlorine Threaded connection Flange connection Power consumption In standby 5 W During changeover Material in contact with the media up to 1400 kg/h Value External thread 1" NPT Flange DN25 / PN40 with key and slot according to EN1092 Inputs: Groove flange (Form D) Output: Tongue flange (Form C) 100 240 V AC max. 100 W steel, Monel, stainless steel, PTFE, silver Pressure gauge Measuring range 0 16 bar (vacuum resistant) Accuracy ± 2.5 % Nominal size Load capacity of the relay contacts Changeover time Operating pressure Ø 63 mm max. 3 A / 250 V AC max. 25 s 0 16 bar 2.2 Dimensions All dimensions in mm 600 550 7 255 1" NPT 300 600 550 1" NPT ~ 550 Fig. 1: Dimensions 1" NPT ~ 242 309 Protection class IP 65 Permissible ambient temperature Weight with mounting plate 0-60 C approx. 17 kg Table 1: Technical data
BW 2 24 04 / 2 2.3 Control box 2.3.1 Controls 1 A Fig. 2: Controls 3 No. Type Function a LED green: Cylinder filled red: Cylinder empty b LED c LED green: Valve yellow: Motor works d LED red: Valve closed A Key 1. notify full cylinder 4 LED switches to green B Key 2. switch manually C Key Close both valves Table 2: Functions of the controls 2.3.2 Functions Automatic battery changeover Should a chlorine supply battery run empty, the pressure in the system will fall and the contact pressure gauge will issue an electrical contact. The control changes the motor ball valves and ensures supply from the other supply battery. The empty supply battery is indicated by a red LED in the cylinder symbol. After connecting the chlorine tank, the operator presses the key in the cylinder symbol. The LED will switch to green and if necessary, the device can switch back to this side. C 4 2 B Manual changeover Manual changeover can be performed with the press of a key. Manual STOP Both valves are closed with the press of a key. Both LEDs in the arrow illuminate red. Jumper JP3 must be closed. Remote indication empty As soon as at least of the the supply batteries has been notified as empty, the relay deactivates and notifies an empty tank. If both batteries are registered as empty, the alarm relay deactivates. Close valves following a gas warning The closure of both valves can be triggered via an electrical contact. The relay contact of a gas warning device is connected to terminal 27/28 to this end. With an active input:: close both valves. The alarm relay deactivates and triggers an alarm. All LEDs flash red. RESET The system restarts afresh after a voltage interruption. Both valves are closed and subject to an electrical test. The system then moves into the standard start position: left valve. Subject to enhancing changes at any time without prior notice.
BW 2 24 04 / 3 2.3.3 Special operating states Operating state LED display: Relays empty Relay alarm Waiting for supply A supply battery is empty, it was subject to automatic changeover, the operating pressure has yet to normalise (waiting time 2 minutes) All empty Both supply batteries are empty or the pressure gauge does not give a contact. A valve is closed A valve is Gas alarm The input contact terminal 27/28 was closed. Both valves are closed Manual STOP Key C was pressed. Both valves are closed Fault Motor was switched to MAN, limit switch in the motor has been incorrectly adjusted or electrical connection between motor and control not OK. Jumper error The jumpers on the control were set to an impermissible combination. Table 3: Signals with special operating states Empty side: cylinder and arrow illuminate red. Active side: cylinder flashes green, arrow illuminates green Both cylinders: illuminate red Valve closed: Arrow illuminates red Open valve: Arrow illuminates green All: flash red OFF ON Both arrows: illuminate red Both cylinders: corresponding state of the cylinder ON ON ON/OFF All: flash red OFF ON OFF ON OFF All: Flashing clockwise. OFF OFF
BW 2 24 04 / 4 2.3.4 Terminal connection Fig. 3: Terminal connection N N' L L' PE PE PE Terminal Description Function N 1 2 3 4 5 6 7 8 9 10 11 12 13 14 close PE N close Vaccum Press. 15 16 17 Com Off On Com Off On POWER IN Motor 2 Motor 1 Alarm empty feedback M2 feedback M1 1+2 N Voltage supply input 3+4 L 5+6 PE 7 PE Voltage supply for motor 2 (ball valve right) 8 N 9 Close 10 Open 11 PE Voltage supply for motor 1 (ball valve left) 12 N 13 Close 14 Open 15 16 Com Off Relay output "alarm" max. 3 A / 250 VAC NC (15-17 closed with power failure) 17 On 18 19 Com Off Relay output "empty" max. 3 A / 250 VAC NC (18-20 closed with power failure) 20 On JP1 JP4 JP3 JP2 JP5 18 19 20 Jumper Processor 21 22 23 24 25 26 27 28 29 30 close GND close GND GasW. GND Mano. GND Table 4: Terminal connection Subject to enhancing changes at any time without prior notice.
BW 2 24 04 / 5 Terminal Description Function 21 close Position switch in motor 2 (ball valve right) 22 23 GND 24 close Position switch in motor 1 (ball valve left) 25 26 GND 27 GasW. Gas warning device input closed = alarm 28 GND 29 Mano. Contact pressure gauge switch closed = chlorine shortage 30 GND Table 4: Terminal connection 2.3.5 Jumper settings The jumpers were set voltage-free The change becomes active once the voltage supply has been switched on. Jumper Name Position Function JP 1 fast closed Both motors activate at the same time. (state of delivery) JP 3 pressure closed (state of delivery) JP 5 Table 5: Jumper rest evacuation closed (delivery state) The reserve battery valve s only after the valve of the active battery has closed. The software of a positive pressure changeover unit is activated. JP1 and JP5 must be. The software of a vacuum changeover unit is activated. Residual emptying activated Residual emptying deactivated
BW 2 24 04 / 6 3 Installation The pre-fitted chlorine gas changeover unit is fitted to the wall with the screws and washers included in the scope of delivery. Devices without a wall plate are supported by the pipe line. The pipe line requires adequate support. The location of installation must be easily-accessible to operating personnel in order to allow manual activation of the changeover unit where necessary. The changeover unit should not be subject to direct sunlight or any other similar bright direct light. This could obscure the operating displays. 3.1 Hydraulic Installation Caution! Changeover is only suitable for use in a chlorinator system in positive pressure. The changeover unit is resistant against pure, dry chlorine (fluid or gaseous). Caution! The connections must be made carefully. Chlorine can also enter the atmosphere of the operation room from small leaks. It will combine with the air moisture to generate a corrosive air. The automatic chlorine cylinder changeover may only be operated with two connected chlorine gas batteries. If only one chlorine gas battery is connected, the non-utilised side be must be closed tightly. Perform the leak test with ammonia. 3.2 Power connections The electrical installation must be performed by a qualified electrician. Ensure that the mains voltage corresponds with the values on the rating plate. Fuse the mains supply line in accordance with local specifications. The changeover unit is ready for operation immediately after connection of the supply voltage. The motors need only be connected with devices without a mounting plate. The plugs are already fitted to the cables and are marked. No. Motor 1 Left valve 2 Right valve Table 6: Number of the motors Where required, the relay contacts for remote indication of the operating state can be connected. The assignment and function of the individual terminals can be taken from the terminal connection plan. Every motor is equipped with an additional position switch for the remote indication of the operating state. It sends the positions OPEN and CLOSED. The terminal connection is pressed directly onto the motor. Superfluous cable screw connections on the control must be sealed in order to maintain the protection class. 3.3 Adjusting the contact pressure gauge The factory settings of the pressure gauge switching contact have been set to c. 4 bar. The system could require calibration of the switching points. The front plate of the pressure gauge must be unscrewed to perform this task. The switching point is then adjusted by moving the red mark within the range 1 to 6 bar. Subject to enhancing changes at any time without prior notice.
BW 2 24 04 / 7 A f e M Fig. 5: Installation example A Room for the chlorine supply 1 Chlorine barrel 2 Chlorine barrel scale 3 Manifold 4 Changeover valve 5 Chlorine gas filter 6 Pressure reducing valve 7 Moisture eliminator with heating collar 8 Vacuum regulator 14 Gas sensor 15 Entrance port of the chlorine eliminator B Dosing device room 9 Dosing device 10 Motive water pump 11 Injector with non-return valve 12 Gas warning device 13 Horn g hr o n B l m i k j
BW 2 24 04 / 8 4 Operation 4.1 Normal mode Automatic changeover Should a chlorine supply battery run empty, the pressure in the system will fall and the contact pressure gauge will issue an electrical contact. The control changes the motor ball valves and ensures supply from the other supply battery. The empty supply battery is indicated by a red LED in the cylinder symbol. Waiting time After changeover, the control undergoes a waiting time of c. 2 minutes, during which time the operating pressure has the opportunity to normalise. This waiting time is shown by the flashing of the green cylinder symbol. RESET for a full chlorine tank After connecting the full chlorine tank, the operator presses the key in the cylinder symbol. The LED will switch to green and if necessary, the device can automatically switch back to this side. Further control functions are described in Chapter 2.3.2. 4.2 Manual mode The motor valve can be activated by hand if necessary (e.g. following a current output). To this end, the changeover lever on the motor is set to manual. The hand grip can then be turned freely. Automatic changeover is now no longer possible. Make sure to return to automatic operation. Turn the hand grip slightly when changing over to automatic operation until it locks in. Label on the motor MAN AUTO Table 7: Motor operating mode Motor operating mode Manual mode Automatic operation 5 Shutdown Chlorine gas is hygroscopic and together with the moisture, forms hydrochloric acid, which destroys the dosing device. As a result, all connections must be closed carefully upon shutdown of the chlorine gas dosing system. All pipes and valves must be flushed with dry air or nitrogen. We recommend storage of the device in a heated dry room after long operation interruptions. When dismantling the device, the lines must be sealed airtight for the reasons outlined above. Look out for condensate in the lines during reactivation. It may be necessary to blow them out with dry air or nitrogen. Subject to enhancing changes at any time without prior notice.
BW 2 24 04 / 9 6 Maintenance 6.1 Maintenance intervals To avoid hazardous incidents, chlorinators must be regularly maintained. We recommend the following maintenance intervals: Interval After 1 year After 3 years After 5 years Table 8: Maintenance intervals Maintenance 6.2 Minor maintenance Minor maintenance: Leak test Functional control Major maintenance: Replace all seals Replace the pressure gauge The device exterior is cleaned and checked for any corrosion damage. Checking for leaks Even the smallest leakages of chlorine will attract moisture and result in the formation of hydrochloric acid. The leakage rate increases quickly due to corrosion. As a result, every leak must be remedied immediately. Leaks are to be located with ammonia solution. Move an cylinder with ammonia along the installation whilst the system is filled with chlorine pressure. Leakages become visible because the ammonia vapour for combines with the chlorine to form a white dust. In particular, pay attention to the following points: All locations on which corrosion is visible. Thread and flange connections Control rods of the ball valves If necessary, the gland screws of the ball valves can be tightened. A description is available in the ball valve instructions. Functional control Operate the changeover unit in normal operation. Both chlorine supply batteries are connected Tank valves are ed One side of the changeover unit ed Injector switched on Connect the tank valves of the active chlorine supply battery. The pressure on the pressure gauge falls and when the switching point has been reached, the ball valves change their switch position. Open the tank valves and press the key in the cylinder symbol. The LED switched to green. Connect the tank valves of the other supply battery. The device must switch back to the other supply side. 6.3 Major maintenance Replace all seals on the ball valves. A description is available in the ball valve instructions. Proceed in the same fashion as in the small maintenance. 6.4 Replace the pressure gauge 1. Disconnect the pressure gauge cable from the control. Unscrew the pressure gauge from the connecting piece. This requires some force, as it is stuck in. 2. Clean the internal thread on T-piece. 3. Glue in the new pressure gauge and allow the glue to harden for 24 hours. Lay the cable to the control and connect it. Pull all the cable screw connections to the control. 4. Adjust the contactor on the pressure gauge to the same value that was set on the pressure gauge. 5. Then perform a leak check and a function test as described under "minor maintenance".
BW 2 24 04 / 10 7 Troubleshooting Problem Possible cause Remedy The changeover unit does not change even though the battery connected is empty and a full battery has been connected to the other side. The changeover unit changes during normal operation, even though the chlorine tank is still full. The valves are not activated subsequently, rather simultaneously. All LEDs flash red. The control shows an unusual illumination or flashing pattern. Table 9: Troubleshooting After connecting the new chlorine tank, the RESET key in the cylinder symbol was not pressed. The voltage supply has been interrupted. All LEDs are off. The maximum supply volume from the battery was exceeded. Possible causes: Insufficient chlorine tanks connected Not all tank valves were ed. Short-term strongly increased extraction due to shock chlorination The switching point on the contact pressure gauge has been adjusted incorrectly. The jumpers in the control have not been connected correctly. A motor has been switched to manual mode A cable connection between the motor and control has been interrupted, the position switch in the motor has been adjusted incorrectly or a motor is defective. The gas warning device contact (terminal 27/28) is closed. The RESET key in the cylinder symbol must be pressed after changing the cylinder. The LED changes from red to green. Reactivate the voltage supply. Connect sufficient chlorine tanks and the valves. Remove simultaneously from both tank batteries for a shock chlorination. Switch the motors on MAN previously. See 3.3 "Adjusting the contact pressure gauge". Adjust the jumpers to the delivery state. See chapter 2.3.5. Set both motors to AUTO Start a manual changeover by pressing the key in the cylinder symbol. Check whether the plugs on the motors are loose. If you do not experience any success: inform Lutz-Jesco service. Locate and redress the cause. A particular operating state is given. See tables in chapter 2.3.3. Subject to enhancing changes at any time without prior notice.
BW 2 24 04 / 11 8 Spare parts 2 1 Fig. 4: General view Position Qty. Description Info Order-No. 1 1 Baseplate PP, 600x600 mm 35790 1 Mounting kit for plate A4 34439 2 2 Servomotor 85-240 V, AC/DC, 90 88820 1 Cam switches adjusting tools W00037 2 Replacement ball valve Innengewinde 1" NPT 22300059 Flansche DN 25 / PN 40 22300060 3 1 Contact pressure gauge Ø63, G1/4 axial 24087653 Ø100, G1/2 unten 24087342 4 1 Control unit complete 100-240 V, 50-60 Hz 22400012 1 Processor (programmed) 79583 IC-gripper (for processor exchange) 79804 Maintenance set for C7520 (after 3 years) 2x maintenance set ball valve 3 from 08 / 2014 onwards 41218 2 4 Table 10: Spare parts